Costain and i3D robotics (i3D), working with Tunnel Engineering Services (UK) Ltd (TES) and the Manufacturing Technology Centre (MTC), have run successful trials of a new assurance system, known as Digitally Assured Tunnel Assets – Information System (DATA-IS).
DATA-IS provides real-time quality and safety assurance of tunnelling fit-out services, such as cable wall brackets. It has been designed to help reduce the cost and time of rework, which has been estimated to account for between 9-38% of total project costs in UK construction, according to research by PlanRadar.
DATA-IS has successfully been trialled alongside ATRIS, an AI-enabled, robotic tunnel installation system launched by the consortium earlier this year. ATRIS automates the process of bracket installation and reduces the health and safety risks associated with tunnel fit-outs.
Live data and information from the services installed by ATRIS are used to complete a digital assurance form to technically assure that an individual bracket has been installed. At the same time, the information is uploaded to a digital twin simulation to provide a remote, real-time visual representation of a successful installation.
When combined, ATRIS and DATA-IS offer an automated tunnel installation and assurance solution, which can be integrated into construction processes used across infrastructure projects in road, rail, water and energy.
Costain developed and implemented the digital twin technology and, along with i3D, managed the integration between the ATRIS and DATA-IS systems. i3D also developed the visualisation software used by ATRIS and optimised its use for DATA-IS. The project was overseen by TES, which conducted trials at its test tunnel facility in Greater Manchester. MTC led the design and manufacture of the ATRIS end effectors and the robot’s programming.
i3D was awarded funding for the project through the Department for Transport’s ‘First of a Kind 2023’ innovation competition, delivered by Innovate UK. As part of the competition there was a specific focus on driving efficiencies in delivery of the rail systems, which includes rails, track, signalling and electrics.
Tony Mallichan, Costain’s digital growth lead for road and rail, said technical and quality assurance was critical for the installation of mechanical and engineering services in tunnels. “But conducting assurance in a tunnelling environment can be a time and labour-intensive process due to the confined space and limited entry or exit points, and can take many months to execute safely.
“Real-time assurance for capital infrastructure projects has the potential to transform efficiency across a project’s lifecycle, providing greater value-for-money and mitigating risk. With the DATA-IS concept, it’s now a reality.
“Working alongside the ATRIS robotics and AI installation system, it is now possible to automate the installation of tunnel services and instantly check the quality and safety of those services against industry benchmarks.”
